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Copper Foil for Beginners Design by Garden Elegance, Fabrication and Text by Dave Burnett T he Freedom Heart is one of many precut kit designs from Garden Elegance by All Cut, Inc. The company also carries mosaic glass clusters, glass shapes, letters and numbers, borders, fusible shapes, and suncatcher kits. The sun catcher kits designs include a Rose, Spectrum Glass Company #200-9W, White for Star and Stripes, 1/2 Sq. Ft. #152W, Red for Stripes, 1/2 Sq. Ft. #136W, Dark Blue for Background, 1/3 Sq. Ft. Materials Required #16400 Freedom Heart Precut Kit Flux Solder 7/32" Copper Foil 20-Gauge Copper Wire Iris, Tulip, Hummingbird, and a Butterfly panel. Suncatcher kits have a round, oval, rectangular, or heart shaped background. Some are available in multiple backgrounds. Every kit includes the precut art glass and pattern and can be assembled like the Freedom Heart. GLASS PATTERNS QUARTERLY/Summer 2003 1 1 5 2 6 3 7 4 8 1. Removing the Glass To keep from breaking the precut pieces of glass, remove them from the package using an X-acto® knife. 2. Foiling the Glass Using the 7/32" copper foil, position the glass in the center of the foil, wrapping the entire piece. Overlap the foil where the ends meet about 1/8". 3. Burnishing the Foil Use a fid or lathkin to burnish the foil. Burnishing smoothes the edges of the foil and adheres the sticky side of the copper foil tape to the glass. Place the foiled pieces on the layout pattern provided with the precut kit. Hold the glass pieces in place with push pins. 4. Fluxing the Panel Using a flux brush, apply the flux to the copper foil lines. Flux comes in a liquid or paste form. The flux etches the copper, which allows it to accept the solder. 5. Soldering the Panel Tack-solder at the joints to keep the pieces of glass from moving. Run a smooth, rounded bead on the front and back of the heart. Tin the outer edge of the heart. 6. Twisting the Wire Using Morton’s Twister, twist together two pieces of 20-guage copper wire long enough to go around the outer edge of the heart. Tin the twisted copper wire. 7. Reinforce the Panel Bend the twisted wire around the outer edge and solder to the edge. This will reinforce the heart and give it a finished edge. 8. Soldering the Hooks Twist the wire to make two hooks for hanging. Solder the hooks onto the back of the heart in the design lines. Clean the project with warm soapy water and flux remover. Patina can be applied in either black or copper. This project was left silver, the color of the solder. Using a glass wax will give a shine to the glass and the solder and prevent oxidation. Attach a silver chain to the hooks and GPQ hang as a suncatcher. 2 GLASS PATTERNS QUARTERLY/Summer 2003 Copper Foil for Beginners When working with glass and solder always work in a well-ventilated area, wear eye protection, and keep a clean work surface. Freedom Heart Design by Garden Elegance Compliments of: GLASS PATTERNS • Q U A R T E R L Y • www.GlassPatterns.com